Connector assembly



April 1s, 1967 E, C DAWS 3,315,214

CONNECTOR ASSEMBLY Filed April 8, 1965 INVENTOR Eff/afd Ecu/5. BY if', MM l United States Patent O 3,315,214 CONNECTUR ASSEMBLY Bayard C. Davis,425 S. Grace, Lombard, Ill. 60148 Filed Apr. 8, 1965, Ser. No. 446,619 3Claims. (Cl. 339-94) This invention relates to electrical connectors andmore particularly to an improved hermetically sealed connector assemblywhich is capable of withstanding adverse environmental conditions andtemperatures in excess of 1800 F.

It is au object of the present invention to provide an improvedelectrical connector assembly.

An additional object of the present invention is to provide ahermetically sealed connector assembly which is capable of withstandingradiation and other adverse environmental conditions as well astemperatures in excess of l800 F.

A further object of the present invention is to provide a temperature,pressure-, and corrosion-resistant metalclad hermetically sealedelectrical connector assembly which can be readily fabricated atmoderate cost and which meets both military and industrialspecifications.

Other objects and advantages of the present invention will becomeapparent from the following description of one preferred embodimentthereof particularly when considered in conjunction with theaccompanying drawing wherein:

FIGURE 1 is an exploded view which depicts the major subcomponents of apreferred embodiment of a connector assembly constructed in accordancewith the present invention;

FIGURE 2 is an enlarged cross-sectional view of the connector assemblyshown in FIGURE 1 when in fully assembled form; and

FIGURE 3 is an enlarged fragmentary cross-sectional view whichillustrates the hermetically sealed connection of one of the connectorpin subassemblies with a metallic sheathed and insulated conductor.

As generally set forth above, the present invention contemplates animproved hermetically sealed connector assembly. In this connection, theconnector assemblies constructed in accordance with the presentinvention may either be of the male or female type and are designed toprovide suitable means for making appropriate connections betweenmetallic sheathed and insulated signalcarrying conductors.

Pursuant `to the present invention, the connector assembly, whether ofthe male or female type, preferably includes a bushing member that isformed of a suitable insulating material and that is suitably aperturedto receive one or more joined electrical contact-conductorsubassemblies. The junction of each contact and associated conductor isconiined within a suitable protective enclosure that is in turnsurrounded by a suitable mounting and sealing sleeve. Preferably, thesealing sleeve provided for each joined contact-conductor subassemblyextends along the conductor, through the apertured bushing member and issecured along with other of the subassembly protective sleeves within asuitable header subassembly that is utilized to elfect the mounting ofthe entire unit within a suitable outer shell or housing. Because of thestructural features of the assembly and as a result of the materialsutilized in the fabrication thereof, a pressure, temperature, andcorrosion-resistant connector is provided which meets `both military andindustrial specications.

Referring more specifically to FIGURE l, a connector assembly isdepicted therein as including an outer shell or housing 11 which ispreferably made of a material such as stainless steel. The housing 11 isshown 3,315,214 Patented Apr. 18, 1967 ICC as having a generallycylindrical configuration with a rectangular flange 11a being formedintegrally with and about the periphery thereof. In a conventionalmanner, the mounting flange 11a is apertured to receive suitablefasteners (not shown) so that the housing can be suitably secured to awall member or similarly mounted on a structure with which the connectorassembly is to be employed. The forward end 11b of the housing 11 isthreaded so that the housing and the connector assembly confined thereincan be secured to a complementing connector assembly, a suitablereceptacle, or similar instrumentality in the usual manner.

In addition to the stainless steel corrosion-resistant housing 11, theconnector assembly 10 also preferably includes an apertured insulatingbushing 12, a yheader subassembly 13 and a plurality of joinedcontact-conductor subassemblies 14. The joined contacts and conductorsare iixedly mounted within the header subassembly 13 by means of sealingand mounting sleeves 15, one of which is associated with each of thesubassernblies 14 as shown in FIGURE 2.

As generally set forth above, the connector assembly 1@ is designedprimarily for use with metallic sheathed and insulated conductors 16.These conductors 16 are typically formed in any desired length with acentral signalcarrying wire 17 that is surrounded by a layer 18 of aceramic insulating material (e.g. MgOl and confined within a metallicprotective sheathing 19 (eg. stainless steel).

In effecting the construction of a connector assembly for use with suchconductors it is necessary to provide a reliable junction between thesignal-carrying wire 17 and a contact Ztl (either male or female) thatcompletes a circuit to the instrumentality to which the connectorassembly is attached. The forming of such a junction must be effected sothat the signal-carrying wire is protected from adverse environmentalconditions (eg. high temperatures, moisture, etc.) While at the sametime being structurally stable.

To this end, the forming of each contact-conductor subassembly ispreferably initiated by stripping a portion of the sheath 19 and layer13 away from one end of a conductor 16. Preferably and as shown inFIGURES 2 and 3, enough of the outer sheath and insulating layer areremoved to insure that the segment 17a of the signalcarrying wire thatis exposed can be securely joined to a contact Ztl.

In this connection, each of the contacts 20 is preferably formed with abored region 20a for receiving the exposed segment 17a of the signalcarrying wire 1'7. In addition,

at least a portion of the bore defining contact 2li is formed.

integrally with a ring-like metallized ceramic insert 22 having anaperture 22a that is aligned with the bored region 20a and that hasouter diameter corresponding to the inner diameter of each of thesleeves 15.

To effect the formation of a sealed junction between the wire 17 andcontact 2t) and to readily facilitate fabrication of a complete assembly1t) as shown in FIGURE 2, the metallized ceramic insert 22 is preferablyinitially joined (eg. by brazing) about a reduced portion of the contact2t) as depicted in FIGURE 3. Thereafter, these joined components aremounted within a free end of a mounting and sealing sleeve 15. That is,the metallized ceramic insert 22 is secured in place adjacent the end ofthe sleeve 15 by means of a copper-brazed connection at the locationdesignated 21 on the inner peripheral surface of the sleeve.

Upon completion of these functions, the sheathed conductor 15 ispositioned within the mounting and sealing sleeve and the segment 17a isjoined to the contact 20. Preferably and as best seen in FIGURE 3, thesegment 17a of the conductor that is to be joined to the contact 20 ispassed through the aperture 22a so that the leading edge portions of thelayer 18 and sheath 19 positively abut the adjacent face of the insert22 and so that the protruding segment of the wire 17 is properlypositioned within the bored region 20a of the contact. When thismounting or positioning is effected, the contact is positively andsecurely joined to the wire 17 as by a brazing, crimping or othersuitable technique. After joining the segment 17a to the contact 20 thesheathed conductor 16 is fixedly mounted in this position within theassociated sleeve 15. This is effected by joining (eg. by brazing) theentire rearward peripheral edge of the sleeve to the peripheral surfaceof the metallic conductor sheath 19 at the location designated by thenumeral 26.

Generally, connector assemblies embodying the present inventionincorporate a plurality of the aforedescribed subassemblies 14 that aremounted in sealed relationship within the sleeves 15. Accordingly, theinsulating bushing 12 is utilized to maintain the subassemblies 14 insuitably spaced relation from each other and from the housing 11 and theheader subassembly 13 is employed to effect the fixed mounting of thesubassemblies 14 within the housing.

More particularly, the bushing 12 is formed of a suitable ceramicinsulating material and is proportioned so that it fits snugly withinthe. housing 11. In addition, the forward peripheral edge of the bushingis slightly rounded to bear against a shoulder portion 11C that isformed on the internal peripheral surface of the housing just forward ofthe mounting flan-ge 11a. The bushing 12 is formed with a plurality ofapertures 12a that extend in parallel relation to the central axisthereof. The apertures 12a are proportioned to receive the sealing andmounting sleeves 15 as shown in FIGURE 2 and allow the contacts to passtherethrough. The apertures 12a are spaced from each other in apreselected manner to insure the proper distribution and location of thecontacts 20 in accordance with preestablished requirements.

` Before the subassemblies that are secured to .and confined within thesleeves 15 are positioned within the bushing 12, these members arejoined to the header subassembly 13. In this connection, the headersubassembly 13 includes a generally cylindrical metallized ceramicinsert 27 that is secured to and confined within a metallic sleeve 28 bya bond at the location designated by the numeral 31, which hond ispreferably effected by .brazing As shown in FIGURE 2, the sleeve 28extends substantially beyond the rearward face of the insert 27, andthis insert is formed with a plurality of suitably proportionedapertures 27a that are arrayed in a configuration corresponding to thearrangement of the apertures 12a in the bushing 12.

The mounting and sealing sleeves 15 that confine the subassemblies 14are positioned within the apertures 27a so that a substantial portion ofeach confined subassembly extends beyond the forward face 27b of theinsert 2'7. This positioning is essential to insure that the contacts 20extend the necessary distance beyond the forward face 12C of the bushing12 after the connector assembly 10 is completed, although with femalecontacts it may be desirable to align the extremities thereof with theface of the bushing, With the subassembly confining sleeves 15 sopositioned within the insert 27, each is secured in position, preferablyby forming a copper-brazed junction at the location designated by thenumeral 29.

To complete the connector assembly 19, the portions of the confinedsubassemblies that extend beyond the forward face 27b of the headerinsert 27 are passed through the apertures 12a in the insulating bushing12. These Ipartially assembled units are then positioned in the housing11, as shown in FIGURE 2. Preferably, the sleeve 28 of the header isformed with dimensions such that the rearward edge of this member issubstantially aligned with the rearward edge of the housing when theaforedescribed connector assembly components are properly andcooperatively positioned within the housing. The fabrication of theconnector assembly 10 is completed by joining the rearward edge portionof the sleeve 28 with that of the housing 11 at the location designatedby numeral 32 by means of a leak-tight, braZed seal or bond.

Although the manner of fabricating connector assemblies embodying thepresent invention may differ somewhat from the technique outlined above,it is preferable that such assemblies include each of the aforedescribedcomponents in essentially the same structural arrangement. That is, suchconnector assemblies preferably include at least one suitably joinedcontact-metallic sheathed and insulated conductor subassembly 14 withthe junction of the components being hermetically sealed by a metallizedceramic insert which is in turn confined within an elongated mountingand sealing sleeve 15.

In addition to housing the sealing insert 22 so that the junction of thecontact-conductor subassembly 14 is appropriately protected, the sleeve15 functions as a support means for a substantial length of theconductor. That is, the sleeve is utilized to effect the final mountingof the contact-conductor subassembly 14 within the header subassembly 13and therefore within the connector housing 11. The assemblies arepreferably completed by the bushing 12 and the header subassembly whichmates with the bushing, although these two individual components can bereplaced by a single mounting and insulating member, when desired.

Specific physical and dimensional characteristics of all of thecomponents forming a preferred embodiment of a connector assembly 10have not been heretofore stated since it is obvious that these just asthe nature of the bonded sealed junctions of the components will bedictated by the particular use to which the assembly is to be put aswell as the environmental conditions to be en countered thereby. Sufficeit to say, as those skilled in the art will appreciate, that themetallic members are preferably formed of materials such as stainlesssteel, Kovar and the like, with the specific preferred material beingselected to withstand the temperature, moisture and other environmentalconditions to he encountered by the assembly. Similarly the insulatingcomponents are selected from materials such as MgO, AlzOg and BeO.Finally, these components, irrespective of the specific materials fromwhich each is formed, will be dimensioned so that each is intimatelymated with its complementary components to thereby insure theelimination of void spots within the `assembly subsequent to thefabrication process as well as a moisture impervious, hermeticallysealed unit that meets both industrial and military specications.

It Will be appreciated Vthat the foregoing is merely illustrative of onepreferred embodiment of a connector assembly constructed pursuant to theteaching of the present invention. For example, assemblies could beformed so that the unit was complete with the exception of the joiningof suitable conductor segments to and within prefabricated and joinedcontact members 2t), insert 22 and confining sleeves 15 that would inturn abe mounted as previously described within a mated bushing 12 andheader assembly 13 in a housing 11. Such units can be readily packagedand, when intended for use, one or`V What is claimed is:

1. A hermetically sealed heat-resistant connector assembly whichcomprises a heat-resistant housing, a plurality of joinedcontact-conductor subassemblies, each of said contact-conductorsubassemblies being formed by a free end of an elongated conductor and acontact element, an insert of insulating material 'being joined to eachof said conductors and intimately surrounding the junction of each ofsaid conductors and contact elements so as to dene a hermetically sealedenclosure for each of said junctions, an elongated sleeve member of eachof said subassemblies, each of said sleeve members having one endthereof joined to and surrounding a corresponding one of said inserts sothat the contact element of sa-id subassembly is exposed, said sleevemember also surrounding a substantial portion of said conductor of saidsubassernbly to facilitate the mounting thereof within said housing, anapertured mounting member positioned in closely iitted relation withinsaid housing, said apertured mounting member conning at least a rportionof each of said sleeve members therein so that each of said members andthe portions of said subassemblies enclosed thereby are insulated fromand maintained in preselected spaced relation to each other and saidhousing, and means securing and hermetically sealing said mountingmember within said housing whereby said subassemblies are confinedWithin said housing so that said contact portion of each is exposed forsuitable mating with external instrumentalities.

2. A connector assembly -in accordance with claim 1 wherein saidmounting member is an apertured insulating bushing that is fitted Withinsaid housing and wherein said securing and sealing means for saidmounting member is a header subassembly that is secured Within saidhousing adjacent said insulating bushing and that is apertured tocomplement said insulating bushing, said header subassembly including anapertured mounting insert through which said sleeve mernibers extend andto which said sleeve members are secured, said header subassembly alsoincluding an outer enclosing sleeve that intimately surrounds andcontines said apertured mounting insert and which is joined in fixedsealing relation to said housing.

3. A connector assembly in accordance with claim 2 and wherein saidjunction surrounding inserts and said apertured mounting insert areformed of a rnetallized ceramic.

References Cited by the Examiner UNITED STATES PATENTS 2,707,273 4/1955Klassen 339-114 X 3,107,135 10/1963 Keil 339-94 X 3,259,871 7/1966Chandler 339-101 X FOREIGN PATENTS 637,564 3/1962 Canada.

MARVIN A. CHAMPION, Primary Examiner. W. DONALD MILLER, Examiner. JOSEPHH. MCGLYNN, Assistant Examiner.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No.3,315,214 April 18, 1967 Bayard C. Davis It is hereby certified thaterror appears in the above numbered patent requiring correction and thatthe said Letters Patent should read as corrected below Column 5, line11, for "of each" read for each line 22, after "said", first occurrence,insert sleeve Signed and sealed this 14th day of November 1967.

(SEAL) Attest:

EDWARD J. BRENNER Edward M. Fletcher, Jr.

Commissioner of Patents Attesting Officer

1. A HERMETICALLY SEALED HEAT-RESISTANT CONNECTOR ASSEMBLY WHICHCOMPRISES A HEAT-RESISTANT HOUSING, A PLURALITY OF JOINEDCONTACT-CONDUCTOR SUBASSEMBLIES, EACH OF SAID CONTACT-CONDUCTORSUBASSEMBLIES BEING FORMED BY A FREE END OF AN ELONGATED CONDUCTOR AND ACONTACT ELEMENT, AN INSERT OF INSULATING MATERIAL BEING JOINED TO EACHOF SAID CONDUCTORS AND INTIMATELY SURROUNDING THE JUNCTION OF EACH OFSAID CONDUCTORS AND CONTACT ELEMENTS SO AS TO DEFINE A HERMETICALLYSEALED ENCLOSED FOR EACH OF SAID JUNCTIONS, AN ELONGATED SLEEVE MEMBERSHAVING SAID SUBASSEMBLIES, EACH OF SAID SLEEVE MEMBERS HAVING ONE ENDTHEREOF JOINED TO AND SURROUNDING A CORRESPONDING ONE OF SAID INSERTS SOTHAT THE CONTACT ELEMENT OF SAID SUBASSEMBLY IS EXPOSED, SAID SLEEVEMEMBER ALSO SURROUNDING A SUBSTANTIAL PORTION OF SAID CONDUCTOR OF SAIDSUBASSEMBLY TO FACILITATE THE MOUNTING THEREOF WITHIN SAID HOUSING, ANAPERTURED MOUNTING MEMBER POSITIONED IN CLOSELY FITTED RELATION WITHINSAID HOUSING, SAID APERTURED MOUNTING MEMBER CONFINING AT LEAST APORTION OF EACH OF SAID SLEEVE MEMBERS THEREIN SO THAT EACH OF SAIDMEMBERS AND THE PORTIONS OF SAID SUBASSEMBLIES ENCLOSED THEREBY AREINSULATED FROM AND MAINTAINED IN PRESELECTED SPACED RELATION TO EACHOTHER AND SAID HOUSING, AND MEANS SECURING AND HERMETICALLY SEALING SAIDMOUNTING MEMBER WITHIN SAID HOUSING WHEREBY SAID SUBASSEMBLIES ARECONFINED WITHIN SAID HOUSING SO THAT SAID CONTACT PORTION OF EACH ISEXPOSED FOR SUITABLE MATING WITH EXTERNAL INSTRUMENTALITIES.